Hydrogen generator with a combustor with a control unit

ABSTRACT

A hydrogen generator ( 1 ) includes: a reformer which generates a hydrogen-containing gas from a raw material and steam; a combustor ( 4 ) which heats the reformer; an evaporator ( 2 ) which generates the steam by utilizing heat of a combustion gas after the reformer is heated by the combustion gas; and a control unit ( 20 ), the hydrogen generator ( 1 ) is controlled such that ON and OFF of a combustion operation of the combustor ( 4 ) are repeated in a start-up operation of the hydrogen generator ( 1 ) and a temperature of the reformer is kept to a predetermined temperature or lower, and the control unit ( 20 ) controls the combustion operation such that a heat amount per unit time by the combustor ( 4 ) in a first combustion operation is larger than the heat amount per unit time in k-th (k&gt;1) and following combustion operations.

RELATED APPLICATIONS

This application is the US National Phase under 35 U.S.C. §371 ofInternational Application No. PCT/JP2007/62121 filed on Jun. 15, 2007,which claims the benefit of Japanese Application No. JP 2006-165855filed on Jun. 15, 2006, the disclosures of which Applications areincorporated by reference herein.

TECHNICAL FIELD

The present invention relates to a hydrogen generator which generates ahydrogen-containing gas by a steam-reforming reaction using as a mainraw material a hydrocarbon-based material, such as natural gas, LPG;gasoline, naphtha, kerosene, or methanol, and a fuel cell systemincluding the hydrogen generator.

BACKGROUND ART

In the hydrogen generator, a raw material containing an organic compoundcomprised of at least carbon and hydrogen is subjected to steamreforming by a reformer including a reforming catalyst layer. Ahydrogen-containing gas is generated by this reforming reaction. Whenthe amount of steam supplied to the reforming catalyst layer in thereforming reaction is inadequate as compared to the amount of the rawmaterial supplied, only the raw material increases in temperature, andflows through the catalyst layer in the reformer and gas passages. Sincethe raw material contains as the main component the organic compoundcomprised of carbon and hydrogen, the raw material is thermallydecomposed under this situation to be a carbon status, and the carbondeposits on the reforming catalyst and in the gas passages. This maycause a decrease in catalytic activity and clogging of the gas passages,thereby disturbing the operation of the hydrogen generator.

It is known that by intermittently carrying out combustion for heatingthe reformer until the temperature of an evaporator which supplies thesteam to the reforming catalyst layer increases to a predeterminedthreshold or higher at the start-up of the hydrogen generator, thetemperature of the reforming catalyst layer can be kept lower than thetemperature at which the carbon deposition occurs (for example, seePatent Document 1 as a conventional example). When the temperature ofthe evaporator exceeds the predetermined threshold, the combustioncontinues, and water supply to the evaporator starts. This start-upmethod can prevent the reforming catalyst from deteriorating.

Patent Document 1: Japanese Laid-Open Patent Application Publication No.2005-170784

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

However, in a case where the combustion using an inappropriatetemperature range and heat amount of the reforming catalyst layer isrepeated in the hydrogen generator of the conventional example, a timetaken to increase the temperature of the evaporator to the predeterminedthreshold may become long. In this case, a time taken to start up thehydrogen generator becomes long. In addition, the number of times ofstart and stop of the combustion tends to be large. As a result, loadwith respect to a combustor and an igniting portion may increase, andthe durability of a structure may also be affected.

An object of the present invention is to provide a hydrogen generatorcapable of increasing the temperature of the evaporator to awater-evaporable temperature within a shorter time than the hydrogengenerator of the conventional example while, by repeating ON and OFF ofa combustion operation of the combustor in a start-up operation of thehydrogen generator, maintaining the temperature of the reformingcatalyst to a temperature lower than the temperature at which the carbondeposition of the raw material occurs, and a fuel cell system includingthe hydrogen generator.

Means for Solving the Problems

In order to solve the above problems, a hydrogen generator of thepresent invention includes: a reformer which generates ahydrogen-containing gas from a raw material and steam; a combustor whichheats the reformer; an evaporator which generates the steam by utilizingheat of a combustion gas after the reformer is heated by the combustiongas; and a control unit, the hydrogen generator is controlled such thatON and OFF of a combustion operation of the combustor are repeated in astart-up operation of the hydrogen generator, and a temperature of thereformer is kept to a predetermined temperature or lower, and thecontrol unit controls the combustion operation such that a heat amountper unit time by the combustor in a first combustion operation is largerthan a heat amount per unit time by the combustor in k-th (k>1) andfollowing combustion operations.

Moreover, the control unit may control the combustion operation suchthat the temperature of the reformer when carrying out OFF of the firstcombustion operation of the combustor is lower than the temperature ofthe reformer when carrying out OFF of the k-th (k>1) and followingcombustion operations.

Moreover, the control unit may control the combustion operation suchthat the temperature of the reformer when carrying out ON of n-th andfollowing combustion operations of the combustor is lower than thetemperature of the reformer when carrying out ON of an m-th (n>m>1)combustion operation of the combustor.

Moreover, the hydrogen generator may further include a water supplyingunit which supplies water to the evaporator, and when a temperature ofthe evaporator becomes a predetermined threshold or higher, the controlunit may not carry out OFF of the combustion operation of the combustorbut continue the combustion operation of the combustor, and causes thewater supplying unit to start supplying the water to the evaporator.

In this case, the predetermined threshold in the first combustionoperation of the combustor may be higher than the predeterminedthreshold in m-th (m>1) and following combustion operations.

Moreover, the combustor may include a burner which burns a combustionfuel and air, a fuel supplying unit which supplies the combustion fuelto the burner, and an air supplying unit which supplies the air to theburner, and the control unit may control the combustion operation suchthat an air ratio of the burner in m-th (m>1) and following combustionoperations is higher than an air ratio of the burner in the firstcombustion operation.

Moreover, an amount of the air supplied to the burner while thecombustion operation is stopped may be larger than an amount of the airsupplied to the burner during the combustion operation.

In the case of increasing the temperature of the evaporator to thewater-evaporable temperature while, by repeating ON and OFF of thecombustion operation of the combustor in the start-up operation of thehydrogen generator, maintaining the temperature of the reformingcatalyst to a temperature lower than a temperature at which the carbondeposition of the raw material occurs, the hydrogen generator of thepresent invention can make the time taken to increase the temperature ofthe evaporator shorter than the hydrogen generator of the conventionalexample, and can make the time taken to start up the hydrogen generatorshorter than the hydrogen generator of the conventional example byvarious controls of the combustor.

Moreover, the air ratio at a time of ignition of the burner may be lowerthan the air ratio in the combustion operation after the ignition of theburner.

With this, the igniting operation of the combustor may be appropriatelycarried out.

The hydrogen generator may further includes: a fuel gas passage throughwhich a gas delivered from the reformer is supplied to the combustor;and a valve which is disposed on the fuel gas passage as the fuelsupplying unit, wherein the control unit may open the valve when aninternal pressure of the reformer reaches a predetermined threshold orhigher while the combustion operation of the combustor is stopped.

With this, depressurizing of the reformer can be appropriately carriedout.

Moreover, the hydrogen generator may further include a raw materialsupplying unit which supplies the raw material to the reformer, whereinthe control unit may cause the raw material supplying unit to supply theraw material into the reformer when an internal pressure of the reformerbecomes a predetermined threshold or lower while the combustionoperation of the combustor is stopped.

With this, pressurizing of the reformer can be appropriately carriedout.

A fuel cell system may include: the above-described hydrogen generator;and a fuel cell which generates electric power by using thehydrogen-containing gas supplied from the hydrogen generator and anoxidizing gas.

The above object, other objects, features and advantages of the presentinvention will be made clear by the following detailed explanation ofpreferred embodiments with reference to the attached drawings.

EFFECTS OF THE INVENTION

In the case of increasing the temperature of the evaporator to thewater-evaporable temperature while, by repeating ON and OFF of thecombustion operation of the combustor in the start-up operation of thehydrogen generator, maintaining the temperature of the reformingcatalyst to a temperature lower than the temperature at which the carbondeposition of the raw material occurs, the hydrogen generator of thepresent invention can make the time taken to increase the temperature ofthe evaporator shorter than the hydrogen generator of the conventionalexample, and can make the time taken to start up the hydrogen generatorshorter than the hydrogen generator of the conventional example. Inaddition, the hydrogen generator of the present invention can reduce thenumber of times of ON and OFF of the combustion operation of thecombustor, reduce the load with respect to the combustor and ignitingportion of the hydrogen generator, and improve the durability of thestructure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-sectional view showing the configuration ofa hydrogen generator in Embodiment 1 of the present invention.

FIG. 2 is a diagram schematically showing time-lapse changes of variousoperating conditions in a first temperature increasing step and a secondtemperature increasing step in a start-up operation using the hydrogengenerator of Embodiment 1 of the present invention.

FIG. 3 is a diagram showing results obtained by compiling the operatingconditions in the first temperature increasing step of the hydrogengenerator in Embodiment 1 of the present invention.

FIG. 4 is a diagram schematically showing time-lapse changes of variousoperating conditions in the first temperature increasing step and thesecond temperature increasing step in another start-up operation usingthe hydrogen generator of Embodiment 1 of the present invention.

FIG. 5 is a diagram schematically showing time-lapse changes of variousoperating conditions in the first temperature increasing step and thesecond temperature increasing step in still another start-up operationusing the hydrogen generator of Embodiment 1 of the present invention.

FIG. 6 is a schematic diagram showing the configuration of a fuel cellsystem in Embodiment 2 of the present invention.

EXPLANATION OF REFERENCE NUMBERS

1 hydrogen generator

2 evaporator

3 reforming catalyst layer

4 combustor

5 radiating tube

6 reforming temperature detector

7 evaporator temperature detector

8 raw material supplying unit

9 water supplying unit

10 fuel supplying unit

11 air supplying unit

20 control unit

30 shift converter

31 CO remover

50 main body

51 vertical wall

52 horizontal wall

53 gap

101 fuel cell

200 fuel cell system

BEST MODE FOR CARRYING OUT THE INVENTION Embodiment 1

Hereinafter, Embodiment 1 will be explained in reference to thedrawings.

FIG. 1 is a schematic cross-sectional view showing the configuration ofa hydrogen generator according to Embodiment 1 of the present invention,and especially shows in detail a reformer, i.e., a main component of ahydrogen generator 1, and its surrounding components.

As shown in FIG. 1, the hydrogen generator 1 is constituted by acylindrical main body 50 whose upper and lower ends are closed, andincludes: a raw material supplying unit 8 which adjusts the amount ofraw material which is comprised of an organic compound containing carbonand hydrogen and supplied to a reformer including a reforming catalystlayer 3; a water supplying unit 9 which adjusts the amount of watersupplied to the reformer; a combustor 4 which heats the reformer; a fuelsupplying unit 10 which adjusts the amount of combustion fuel suppliedto the combustor 4; an air supplying unit 11 which adjusts the amount ofair supplied to the combustor 4; and a control unit 20. Specificexamples of these supplying units are a flow rate control valve and apump.

In the hydrogen generator 1, a plurality of cylindrical vertical walls51 which are different in radius and axial length from one another areconcentrically disposed inside the cylindrical main body 50. With this,the inside of the main body 50 are defined in a radial direction. Adisc-shaped or hollow disc-shaped horizontal wall 52 is suitablydisposed on predetermined end portions of the vertical walls 51. Indetail, gaps 53 are formed between the vertical walls 51 byconcentrically and perpendicularly disposing a plurality of the verticalwalls 51 inside the main body 50, and the predetermined end portions ofthe vertical walls 51 are suitably closed by the horizontal wall 52 suchthat desired gas passages are formed by utilizing the gaps 53. Thus, areforming raw material passage a, a combustion gas passage b1, acombustion gas passage b2, a hydrogen-containing gas passage c, and thereforming catalyst layer 3 are formed inside the main body 50, and thesepassages are formed in this order from an outer peripheral side of themain body 50 toward a center thereof in the radial direction of the mainbody 50.

An upstream end portion of the reforming raw material passage a isconnected to the raw material supplying unit 8 and the water supplyingunit 9 disposed outside the main body 50, and a downstream end portionof the reforming raw material passage a is connected to an upper endsurface of the reforming catalyst layer 3. The reforming raw materialpassage a has a dual structure, and has a rising structure such that amoving direction of a material moving in the passage changes from adownward axial direction to an upward axial direction. An evaporator 2is formed at a bottom portion of the reforming raw material passage a.As will be described later, water supplied from the water supplying unit9 is evaporated by the evaporator 2, and is supplied to the reformingcatalyst layer 3. An evaporator temperature detector 7 which detects thetemperature of a wall corresponding to the evaporator is disposed on theevaporator 2. Herein, a thermocouple is disposed as the evaporatortemperature detector 7. An installation location of the evaporatortemperature detector 7 is not especially limited as long as it is such alocation that the evaporator temperature detector 7 can detect thetemperature of the vertical wall 51 or the horizontal wall 52 formingthe evaporator 2. Herein, the evaporator temperature detector 7 isdisposed to detect the temperature of an outer wall surface of theevaporator 2, and a temperature estimated from the detected temperatureof the outer wall surface is regarded as the temperature of theevaporator 2. However, for example, the evaporator temperature detector7 may be configured to directly detect the temperature of the bottomsurface of an inner wall of the evaporator 2 or the temperature of waterremaining at a bottom portion of the evaporator 2. Information about thetemperature of the evaporator 2 detected by the evaporator temperaturedetector 7 is transmitted to the control unit 20. In accordance withthis temperature information, the control unit 20 outputs a supply startsignal, a supply stop signal, and a flow rate change signal to the rawmaterial supplying unit 8, the water supplying unit 9, the fuelsupplying unit 10, and the air supplying unit 11.

The reforming catalyst layer 3 is formed by filling up the gap 53 withreforming catalyst, and is disposed along an upper end surface and outerperipheral surface of a radiating tube 5 of the below-describedcombustor 4. Herein, the reforming catalyst containing Ru as the maincomponent is used. However, the reforming catalyst is not especiallylimited as long as it enables the reforming reaction. For example, thereforming catalyst may be comprised of a precious metal, such as Pt orRh, Ni, or the like. The upper end surface of the reforming catalystlayer 3 is connected to the reforming raw material passage a, and alower end surface of the reforming catalyst layer 3 is connected to anupstream end portion of the hydrogen-containing gas passage c. Areforming temperature detector 6 which detects the temperature of a gashaving passed through the reforming catalyst layer 3 and flowing in thepassage is disposed inside the hydrogen-containing gas passage c.Herein, a thermocouple is disposed as the reforming temperature detector6. An installation location of the reforming temperature detector 6 isnot especially limited as long as it is such a location that thereforming temperature detector 6 can directly or indirectly detect thetemperature of the reformer. Herein, the reforming temperature detector6 is disposed to detect the temperature of the gas which has just passedthrough the reforming catalyst layer 3, and the detected temperature ofthe gas is regarded as the temperature of the reformer. However, forexample, the reforming temperature detector 6 may be configured todirectly detect the temperature inside the reforming catalyst layer 3,or may be configured to detect the temperature of the vertical wall 51or the horizontal wall 52 forming the reforming catalyst layer 3.Information about the temperature of the reformer detected by thereforming temperature detector 6 is transmitted to the control unit 20.In accordance with this temperature information, the control unit 20outputs the supply start signal, the supply stop signal, and the flowrate change signal to the raw material supplying unit 8, the watersupplying unit 9, the fuel supplying unit 10, and the air supplying unit11.

The combustor 4 is constituted by a burner 4 a, and burns a combustionfuel supplied from the fuel supplying unit 10 and air supplied from theair supplying unit 11 to generate a flame. The radiating tube 5 isdisposed at an upper portion of the combustor 4, is stored inside themain body 50 of the hydrogen generator 1, and is disposed concentricallywith the main body 50 of the hydrogen generator 1. Flame is generatedinside the radiating tube 5, and its combustion gas flows through thecombustion gas passage b2 inside the hydrogen generator 1. Thecombustion gas passage b2 and the combustion gas passage bl arecommunicated with each other at their bottom portions, and a downstreamend portion of the combustion gas passage bl is configured such that thecombustion gas can be taken out to the outside of the hydrogen generator1.

The control unit 20 is constituted by a computer, such as amicrocomputer. The control unit 20 controls the raw material supplyingunit 8, the water supplying unit 9, the fuel supplying unit 10, and theair supplying unit 11 to adjust supply amounts of the raw material, thewater, the combustion fuel, and the air. Each of the raw materialsupplying unit 8, the water supplying unit 9, the fuel supplying unit10, and the air supplying unit 11 is configured to be able to adjust theflow rate of a supply target. For example, each of these supplying unit8, 9, 10, and 11 may be configured to include a mechanical or electricalactuating device, such as a pump or a fan, and configured such that theactuating device is controlled by the control unit 20 to adjust eachsupply flow rate. Moreover, each of these supplying unit 8, 9, 10, and11 may be configured such that a flow rate adjuster, such as a valve, isfurther disposed at a downstream passage of the actuating device, andthe flow rate adjuster is controlled by the control unit 20 to adjusteach supply amount.

Next, the outline of a start-up operation of the hydrogen generator 1will be explained. The start-up operation of the hydrogen generator 1starts in accordance with a start-up command output from the controlunit 20. This start-up operation mainly includes a step (hereinafterreferred to as a first temperature increasing step) of heating theevaporator 2 to such a temperature that the evaporator 2 can generatesteam, and a step (hereinafter referred to as a second temperatureincreasing step) of heating the reformer to a reforming reactiontemperature while supplying the water to the evaporator 2 heated to theabove temperature. When the second temperature increasing step iscompleted, and adequate hydrogen is generated by the reforming reactionin the reforming catalyst layer 3, the start-up operation is completed,and a normal operation (hereinafter referred to as a hydrogen generatingstep) of the hydrogen generator 1 is started.

In the first temperature increasing step, the temperature detected bythe reforming temperature detector 6 is kept to a first predeterminedtemperature or lower until the temperature detected by the evaporatortemperature detector 7 reaches a water-evaporable temperature. The firstpredetermined temperature is a temperature at which the reformingcatalyst does not deteriorate in the absence of steam and the carbondeposition of the supplied raw material does not occur in the absence ofsteam. It is preferable that a set temperature of the firstpredetermined temperature be in a range from 300 to 500° C. In thepresent embodiment, the set temperature of the first predeterminedtemperature is 380° C. or lower. The set temperature of the firstpredetermined temperature may be the other temperature as long as it isa temperature at which the reforming catalyst does not deteriorate andthe carbon deposition of the raw material does not occur.

When the temperature detected by the evaporator temperature detector 7exceeds the water-evaporable temperature, the process switches from thefirst temperature increasing step to the second temperature increasingstep. When the temperature of the reforming catalyst layer 3 reaches thereforming reaction temperature (for example, 500° C. to 700° C.) by thesecond temperature increasing step, a hydrogen-containing gas isgenerated from the raw material and the steam by the reforming reactionusing the reforming catalyst, and thereby, the process switches from thesecond temperature increasing step to the hydrogen generating step.Herein, a period from the start of the combustion of the combustor 4 tothe supply of the water to the evaporator 2 is called a firsttemperature increasing time as a time taken to carry out the firsttemperature increasing step of the hydrogen generator 1.

The operations of the hydrogen generator 1 in the first temperatureincreasing step, the second temperature increasing step, and thehydrogen generating step are controlled by the control unit 20.

At the beginning of the start-up of the hydrogen generator 1 (firsttemperature increasing step), the fuel supplying unit 10 supplies thecombustion fuel at a predetermined flow rate to the combustor 4, and theair supplying unit 11 supplies the air at a predetermined flow rate tothe combustor 4. The combustor 4 generates a flame inside the radiatingtube 5 by the combustion reaction between the supplied combustion fueland air. The reforming catalyst layer 3 in the reformer is heated bycombustion heat generated by the combustion, and is heated also bypotential heat of the combustion gas which is introduced from theradiating tube 5 to the combustion gas passage b2 and flows in thepassage.

Further, the combustion gas is introduced from the combustion gaspassage b2 to the combustion gas passage b1, and flows in the passage.Since the combustion gas passage b1 is in contact with the reforming rawmaterial passage a via the vertical wall 51, the heat of the combustiongas flowing through the combustion gas passage b1 is transferred to thereforming raw material passage a. Thus, the evaporator 2 disposed on aninner peripheral side of the combustion gas passage b1 via the verticalwall 51 is heated. As above, both the reformer (reforming catalyst layer3) and the evaporator 2 are heated by the combustion of the combustor12, and the reformer (reforming catalyst layer 3) located on an upstreamside in a heat transfer passage is heated before the evaporator 2located on a downstream side in the heat transfer passage is heated.

When heating the reformer, the temperature of the hydrogen-containinggas having passed through the reforming catalyst layer 3 is detected bythe reforming temperature detector 6, and the detected temperature ofthe hydrogen-containing gas is transmitted to the control unit 20. Whenthe temperature detected by the reforming temperature detector 6 reachesthe first predetermined temperature or higher, the temperature of theevaporator 2 is detected by the evaporator temperature detector 7. Whenthe detected temperature of the evaporator 2 is a predeterminedthreshold or higher, it is determined that water evaporation can becarried out by the evaporator 2. In this case, water supply to thereformer is started, and the hydrogen generator 1 proceeds to the secondtemperature increasing step. The predetermined temperature set for thereformer and the predetermined threshold set for the evaporator 2 willbe described later.

In the present embodiment, in the start-up operation and steadyoperation of the hydrogen generator 1, the hydrogen-containing gashaving flown through the hydrogen-containing gas passage c is suppliedto the combustor 4 as the combustion fuel via a passage, not shown, theamount of the combustion fuel supplied to the combustor 4 is adjusted bythe raw material supplying unit 8, and the raw material supplying unit 8functions as a fuel supplying unit of supplying fuel to the combustor 4.However, the present embodiment may be configured such that thecombustion fuel is supplied via a passage on which the fuel supplyingunit 10 is disposed as shown in FIG. 1 in addition to the passageextending from the hydrogen-containing gas passage c to the combustor 4,and the raw material supplying unit 8 and the fuel supplying unit 10function as a combustion fuel supplying unit. In this case, for example,the raw material supplying unit 8 may be operated such that: until thecombustion fuel having passed through the hydrogen-containing gaspassage c in the start-up operation is supplied to the combustor 4, thecombustion fuel is supplied to the fuel supplying unit 10 for ignitionand combustion; and when the combustion fuel having passed through thehydrogen-containing gas passage c is supplied to the combustor 4, onlythe combustion fuel having passed through the hydrogen-containing gaspassage c is supplied to the combustor 4. Moreover, the raw materialsupplying unit 8 may be configured such that: the combustion fuel issupplied to the combustor 4 from only the fuel supplying unit 10 untilthe second temperature increasing step is completed; and when startinggenerating hydrogen, the raw material is supplied from the raw materialsupplying unit 8.

Meanwhile, when the temperature detected by the reforming temperaturedetector 6 reaches the first predetermined temperature or higher, thetemperature of the evaporator 2 is detected by the evaporatortemperature detector 7. When the detected temperature of the evaporator2 is lower than the predetermined threshold, it is determined that thewater evaporation cannot be carried out by the evaporator 2. In thiscase, the combustion operation of the combustor 4 is stopped, and theamount of air supplied from the air supplying unit 11 is increased tocool down the reforming catalyst layer 3 by the air. In the presentspecification, an operation in which the combustion operation of thecombustor 4 is carried out is defined as “ON”, and an operation in whichthe combustion operation of the combustor 4 is stopped is defined as“OFF”. Moreover, in the present specification, the “combustionoperation” of the combustor 4 is defined as a temperature increasingoperation of the combustor 4 which can increase the temperature of thereformer by a predetermined temperature. Therefore, the “combustionoperation” does not include such combustion failure that the combustor 4has been ignited but soon extinguishes its flame due to unstablecombustion or the like, or just an “igniting operation” of the combustor4 which does not contribute to the increase in temperature of thereforming catalyst layer 3.

When the combustion operation of the combustor 4 is stopped, and thetemperature detected by the reforming temperature detector 6 becomes thesecond predetermined temperature or lower, the combustion operation ofthe combustor 4 is restarted. When the temperature detected by thereforming temperature detector 6 reaches the first predeterminedtemperature or higher again, the temperature of the evaporator 2 isdetected by the evaporator temperature detector 7. Then, whether or notthe detected temperature of the evaporator 2 is the predeterminedthreshold or higher is determined to determine whether to stop thecombustion operation of the combustor 4 or proceed to the secondtemperature increasing step.

In the second temperature increasing step, the raw material suppliedfrom the raw material supplying unit 8 and the steam generated bycausing the water supplied from the water supplying unit 9 to beevaporated by the evaporator 2 flow through the reforming raw materialpassage a to be supplied to the reforming catalyst layer 3. Afterpassing through the reforming catalyst layer 3, the raw material and thesteam are supplied to the hydrogen-containing gas passage c. The gashaving passed through the reforming catalyst layer 3 is taken out to theoutside of the reformer via the hydrogen-containing gas passage c. Whenthe temperature of the reforming catalyst layer 3 heated in a statewhere the raw material and the steam pass therethrough reaches thereforming reaction temperature, the reforming reaction is carried out bythe raw material and the steam to generate hydrogen. It should be notedthat the reforming reaction is not suddenly started at a certainthreshold temperature. That is, when the temperature of the reformingcatalyst layer 3 reaches about 500° C., a part of the supplied rawmaterial and a part of the supplied steam start reacting with eachother, and the ratio of the reacting raw material and steam to theentire raw material and steam increases as the increase in temperature.When the temperature of the reforming catalyst layer 3 reaches about700° C., the raw material and the steam almost completely react witheach other. Therefore, in the second temperature increasing step inwhich the reformer is heated in a state where the raw material and thesteam are supplied, the reforming reaction is suitably started when acondition of the temperature detected by the reforming temperaturedetector 6 is met. Herein, a state in which the temperature detected bythe reforming temperature detector 6 is about 700° C. for example, andthe raw material and the steam supplied to the reformer almostcompletely react with each other to generate hydrogen is called thehydrogen generating step. Therefore, although the operation of heatingthe reformer until the reforming catalyst layer 3 reaches the reformingreaction temperature is defined as the second temperature increasingstep, hydrogen is partially generated by the reforming reaction from theraw material and the steam even in the period of the second temperatureincreasing step.

Note that the hydrogen generating step of the hydrogen generator 1 isthe same as a normal operation of an existing hydrogen generator 1. Tobe specific, the hydrogen-containing gas containing hydrogen as the maincomponent is generated in the reforming catalyst layer 3 by using theraw material and the steam supplied to the reforming catalyst layer 3via the reforming raw material passage a and the reforming catalyst. Thegenerated hydrogen-containing gas is taken out to the outside of thereformer via the hydrogen-containing gas passage c, and is utilized insuitable applications (for example, utilized as an electric powergenerating fuel of a below-described fuel cell system).

Next, details of the operation of the first temperature increasing stepwill be explained in reference to the drawings.

FIG. 2 is a diagram schematically showing time-lapse changes of variousoperating conditions in the first temperature increasing step and (in upto an intermediate point of) the second temperature increasing step inthe start-up operation using the hydrogen generator according toEmbodiment 1 of the present invention. In FIG. 2, a horizontal axisdenotes an elapsed time (hour:minute) since the beginning of thestart-up of the hydrogen generator 1, and representative examples of theoperating conditions of the hydrogen generator 1 are: the temperature (°C.) detected by the reforming temperature detector 6; the temperature (°C.) of the evaporator 2 detected by the evaporator temperature detector7; the flow rate (abbreviated as “raw material flow rate” in thefollowing explanation and the drawings according to need) (numericalvalue ×10⁻² NLM; liter (L)/minute (min)[normal]) of the fuel of thecombustor 4 adjusted by the raw material supplying unit 8 and the fuelsupplying unit 10; and the number of rotations (numerical value×10 rpm)of a combustion fan, i.e., the air supplying unit 11 adjusted by thecombustion fan.

First, when starting the start-up operation of the hydrogen generator 1,the control unit 20 checks the temperature detected by the reformingtemperature detector 6 to confirm whether or not the temperature is sucha temperature that the catalyst deterioration and the carbon depositionof the raw material do not occur even when the raw material is suppliedto the reforming catalyst layer 3. If the temperature is such atemperature that the catalyst deterioration and the carbon deposition ofthe raw material occur, air is supplied from the air supplying unit 11to cool down the reforming catalyst layer 3. Then, the start-upoperation is started. When the temperature of the reforming catalystlayer 3 is equal to or lower than such a temperature that the catalystdeterioration and the carbon deposition of the raw material do not occureven when the raw material is supplied, the raw material is supplied tothe reformer from the raw material supplying unit 8, and thus, the gasin the reformer is replaced with the raw material. With theseoperations, even when the temperature of the evaporator 2 has notreached the water-evaporable temperature, and the temperature of thereforming catalyst layer 3 is such a high temperature that the carbondeposition of the raw material occurs, the gas inside of the reformercan be appropriately replaced with the raw material.

In the present embodiment, the raw material used for the replacement issupplied as the combustion fuel to the combustor 4 via thehydrogen-containing gas passage c, and is used for the combustion of thecombustor 4. The gas used for the replacement does not have to be usedfor the combustion of the combustor 4. For example, the gas used for thereplacement may be diluted by the air, which is supplied from the airsupplying unit, to a level at which the gas is burnable, and dischargedto the atmosphere. In the present embodiment, the raw material is causedto flow through the hydrogen generator 1 (reformer) in the start-upoperation because the raw material is used as a heat exchange medium ofheating the entire hydrogen generator 1 to speed up the increase intemperature of the entire hydrogen generator 1. Therefore, it ispreferable that the supply of the raw material to the hydrogen generator1 be carried out in the start-up in addition to the replacementoperation.

Next, the reformer is heated by burning in the combustor 4 thecombustion fuel supplied from the hydrogen-containing gas passage c anda passage on which the fuel supplying unit 10 is disposed and the airsupplied from the air supplying unit 11. In the present embodiment, acombustion method of the combustor 4 is diffusion combustion. However,it may be premix combustion as long as the combustion can be carriedout. The reforming catalyst layer 3 is heated by the combustion of thecombustor 4, and the temperature detected by the reforming temperaturedetector 6 also increases.

Here, the control unit 20 controls the combustion operation(specifically, the operation of the raw material supplying unit 8) ofthe combustor 4 such that the flow rate (corresponding to the “rawmaterial flow rate” shown in FIG. 2 as the operating condition) of thecombustion fuel supplied to the combustor 4 is increased only in thefirst combustion operation, and thus, a heat amount per unit time isincreased. In the present embodiment, as shown in FIG. 2, the flow rate(raw material flow rate) of the combustion fuel in the first combustionoperation is adjusted to 2.0 NLM by the control unit 20, and the flowrate of the combustion fuel in the second and following combustionoperations are adjusted to 1.5 NLM by the control unit 20. Since thetemperature inside the reformer is not adequately high in the firstcombustion operation, a large amount of heat is required to heat theentire reformer. This is because if the amount of heat per unit timesupplied from the combustor 4 is not increased, a time taken to heat thereforming catalyst layer 3 to the first predetermined temperaturebecomes long, and thereby, a time taken to carry out the firsttemperature increasing step becomes long. Since the temperature of theentire reformer is high in the second and following combustionoperations, it is preferable that the flow rate of the combustion fuelbe lower than that in the first combustion operation. Note that the flowrate of the combustion fuel at the time of the ignition of the combustor4 in the first combustion operation is equal to that in the second andfollowing combustion operations. To be specific, as shown in FIG. 2, theflow rate at the time of rising of the raw material fuel, whichcorresponds to the time of the ignition of the combustor 4, is adjustedto 1.5 NLM in both the first combustion operation and the second andfollowing combustion operations. A purpose of adjusting the flow rate isto keep the stability of the ignition of the combustor 4. Therefore, theflow rate of the combustion fuel at the time of the ignition in thefirst combustion operation may be set to be higher than that in thesecond and following combustion operations as long as the ignition canbe stably carried out.

Moreover, an air ratio of the combustor 4 at the time of the ignition ofthe combustor 4 may be set to be lower than the air ratio of thecombustor 4 in the combustion operation of the combustor 4 after theignition. With this, it is expected that the air ratio of the combustor4 at the time of ignition of the combustor 4 becomes close to “1”, andthe ignition of the combustor is facilitated.

Moreover, the control unit 20 controls the operations of the rawmaterial supplying unit 8 and the air supplying unit 11 such that theair ratio of the combustor 4 in the second and following combustionoperations is higher than the air ratio of the combustor 4 in the firstcombustion operation. To be specific, the ratio of the air to thecombustion fuel in the second and following combustion operations ishigher than that in the first combustion operation.

Note that the above-described air ratio refers to a ratio (A/A₀) of anamount A of the air actually supplied, to a theoretical amount (minimummount of air necessary to completely burn the combustion fuel) A₀ of theair. Incomplete combustion of the combustion fuel occurs when the airratio is lower than “1”.

As the air ratio increases, the ratio of the air to the combustion fuelincreases, and a flow velocity of the combustion gas changes. Therefore,when the air ratio increases, heat is more likely to be transferred tothe evaporator 2 which carries out the heat exchange with the combustiongas passage b1 and the combustion gas passage b2, whereas the heat isless likely to be transferred to the reforming catalyst layer 3. On thisaccount, the air ratio is adjusted to be low in the first combustionoperation such that the reforming catalyst layer 3 located on anupstream side of the combustion gas is easily heated (for example, theair ratio is adjusted to a standard air ratio used in a normalcombustion operation of the combustor 4), and the air ratio is adjustedto be high in the second and following combustion operations such thatthe evaporator 2 is easily heated (for example, the air ratio isadjusted to exceed the above-described standard air ratio).

The number of rotations of the combustion fan is shown in FIG. 2 as theoperating condition corresponding to the flow rate of the air suppliedto the combustor 4. FIG. 2 shows that the number of rotations of thecombustion fan tends to substantially monotonically increase in thecombustion operation of the combustor 4. It is understood that: theincrease in temperature of the reformer is appropriately handled byincreasing the number of rotations of the combustion fan; and the outputof the air supplying unit 11 is adjusted such that when the flow rate(raw material flow rate) of the combustion fuel supplied to thecombustor 4 is constant, the flow rate of the air supplied to thecombustor 4 also becomes constant. When the temperature of the reformerincreases, airflow resistance produced when supplying the air to thecombustor by the air supplying unit 11 increases because of volumeexpansion of the combustion fuel discharged from the reformer to reachthe combustor 4 and the decrease in volume shrinkage ratio of thecombustion gas due to the increase in temperature of the hydrogengenerator 1. Therefore, as shown in FIG. 2, if the number of rotationsof the combustion fan is not increased, the flow rate of the air cannotbe kept constant.

In the combustion operation, the control unit 20 heats the reformer bythe combustor 4, and detects the temperature of the evaporator 2 by theevaporator temperature detector 7 when the temperature detected by thereforming temperature detector 6 has reached the first predeterminedtemperature or higher. Here, the first predetermined temperature of thereforming catalyst layer 3 is such a temperature that the reformingcatalyst does not deteriorate, and the carbon deposition of the rawmaterial does not occur under a situation where there is no water. To bespecific, the first predetermined temperature is set as a referencetemperature for determining whether or not the evaporator 2 canevaporate the water, and as described above, is set to a temperaturelower than the temperature at which the carbon deposition of the rawmaterial occurs in the reforming catalyst layer 3.

In the case of the above-described material of the reforming catalystlayer 3, a specific set temperature is preferably in a range from 300 to500° C. In the present embodiment, it is set to 380° C. or lower. Forexample, the first predetermined temperature is set to 360° C. in thefirst combustion operation, and 370° C., i.e., a higher temperature thanthe above in the second and following combustion operations. The reasonwhy the first predetermined temperature is changed between the firstcombustion operation and the second and following combustion operationsis that the flow rate of the combustion fuel is different therebetween.In the present embodiment, as described above, the flow rate of thecombustion fuel in the first combustion operation is higher than that inthe second and following combustion operations. Therefore, when thecombustion operation is stopped, the temperature of the reformingcatalyst layer 3 tends to overshoot in the first combustion operation.On this account, in order to keep the temperature detected by thereforming temperature detector 6 to 380° C. or lower, it is necessarythat the first predetermined temperature is 360° C. in the firstcombustion operation, and 370° C. in the second and following combustionoperations. The set temperature is not limited to 380° C. or lower,since it changes depending on the configuration of the hydrogengenerator 1, the catalyst to be used, a temperature detecting method,and the like. Moreover, the first predetermined temperature should beset appropriately for each generator because the tendency of occurrenceof the overshoot of the temperature of the reforming catalyst layer 3when the combustion is stopped changes depending on the configuration ofthe hydrogen generator 1, the catalyst to be used, the temperaturedetecting method, and the like.

When the temperature detected by the reforming temperature detector 6has reached the first predetermined temperature or higher determined dueto the above reasons, the control unit 20 detects the temperature of theevaporator 2 by the evaporator temperature detector 7 to determinewhether or not the temperature of the evaporator 2 is thewater-evaporable temperature. Here, the water-evaporable temperatureshould be set to 100° C. or higher. However, in the configuration of thepresent embodiment, as described above, since the evaporator temperaturedetector 7 is disposed on the outer wall surface of the vertical wall 51or the horizontal wall 52 forming the evaporator 2, the temperaturedetected by the evaporator temperature detector 7 is lower than anactual internal temperature of the evaporator 2. Therefore, thewater-evaporable temperature detected by the evaporator temperaturedetector 7 as the water-evaporable temperature is set to a temperaturelower than 100° C., i.e., 90° C. in the first combustion operation and85° C. in the second and following combustion operations. The set valueof the water-evaporable temperature is changed between the firstcombustion operation and the second and following combustion operationsin order to deal with a case where the start-up is carried out in astate where the temperature of the hydrogen generator 1 is still highafter the operation of the hydrogen generator 1 is stopped (hereinafterreferred to as a hot start). When the hot start of the hydrogengenerator 1 is carried out, the temperature of the evaporator 2 is highat the beginning of the start-up. However, the temperature of theevaporator 2 may tend to decrease in the first combustion operation ofthe first temperature increasing step. To be specific, in the presentembodiment, as described above, since the air ratio in the combustion ofthe combustor 4 is low in the first combustion operation, the evaporator2 is less likely to be heated in the first combustion operation than inthe second and following combustion operations. Therefore, in a casewhere the water-evaporable temperature in the first combustion operationand the water-evaporable temperature in the second and followingcombustion operations are set to the same set value (85° C. herein), anadequate amount of heat may not be supplied to the evaporator 2 after itis determined that the evaporator 2 can evaporate the water. On thisaccount, the temperature of the evaporator 2 may keep on decreasing, andwhen the water is supplied from the water supplying unit 9, the watermay not be evaporated. Therefore, the set value of the water-evaporabletemperature in the first combustion operation is set to be higher thanthe set value of the water-evaporable temperature in the second andfollowing combustion operations.

The control unit 20 uses the set value of the water-evaporabletemperature to determine whether or not the temperature of theevaporator 2 is the water-evaporable temperature. When the temperatureof the evaporator 2 is the water-evaporable temperature (when thetemperature detected by the evaporator temperature detector 7 is equalto or higher than the set value of the water-evaporable temperature),the water is supplied from the water supplying unit 9 while continuingthe combustion operation of the combustor 4, and the process proceeds tothe second temperature increasing step. The operations thereafter havealready been described above, so that explanations thereof are omitted.In contrast, when the temperature of the evaporator 2 is not thewater-evaporable temperature (when the temperature detected by theevaporator temperature detector 7 is lower than the set value of thewater-evaporable temperature), in order to keep the temperature detectedby the reforming temperature detector 6 to 380° C. or lower, thecombustion operation of the combustor 4 is stopped by stopping supplyingthe combustion fuel from the fuel supplying unit 10. For example, thecontrol unit 20 closes the flow rate control valve of the raw materialsupplying unit 8 to stop the combustion operation of the combustor 4.Moreover, in order to cool down the reforming catalyst layer 3 by theair, the amount of air supplied from the air supplying unit 11 to thecombustor 4 is increased as compared to the amount of air in thecombustion operation. At this time, since the temperature of thereforming catalyst layer 3 is higher than the temperature of theevaporator 2, heat is transferred from the reforming catalyst layer 3 tothe evaporator 2 by the air used to cool down the reforming catalystlayer 3, so that heating the evaporator 2 is carried out while thecombustion is stopped.

Since a temperature distribution of the entire reformer and hydrogengenerator 1 changes while the reforming catalyst layer 3 is cooled downby the air, the temperature of the raw material filled in the reformerand the hydrogen generator 1 changes, and the volume thereof alsochanges. The temperature change of the reforming catalyst layer 3differs between a portion on an upstream side of the air cooling and aportion on a downstream side of the air cooling. When the temperature ofthe reforming catalyst layer 3 increases, the volume thereof expands,and an internal pressure increases. When the temperature of thereforming catalyst layer 3 decreases, the volume thereof contracts, andthe internal pressure decreases. If the pressure inside the generatorbecomes too high or too low, the pressure may be applied to devices,such as a valve and a supply pump disposed in the reformer, and thestructure of the reformer, causing these devices to degrade theirdurability and to be damaged. Therefore, in a case where the internalpressure of the reformer exceeds a predetermined value, the control unit20 causes an on-off valve (not shown) disposed on a passage extendingfrom the hydrogen-containing gas passage c to the combustor 4 totemporarily open, thereby discharging the gas (combustible gas, such asthe raw material and the like) from the reformer to the combustor 4 fordepressurizing. Thus, the internal pressure of the reformer can bedecreased. The combustible gas discharged to the combustor 4 is dilutedinside the combustor 4 by the air supplied by the air supplying unit 11,and is discharged to the outside. In the present embodiment, thedepressurizing is carried out such that the internal pressure of thepassage formed downstream of the reformer in the hydrogen generator 1 iskept to 3 kPa or lower. This value of the internal pressure changesdepending on the configuration of the generator, so that the internalpressure is not limited to this value. An appropriate value of theinternal pressure should be set to suit each generator.

Moreover, when the internal pressure of the hydrogen generator 1 islower than the predetermined value, the control unit 20 causes the rawmaterial supplying unit 8 to supply the raw material to the inside ofthe reformer. Thus, the internal pressure of the hydrogen generator 1can be increased (In this case, the on-off valve is closed.). In thepresent embodiment, pressurizing is carried out such that the internalpressure of the hydrogen generator 1 is kept to 0.5 kPa or higher. Thisvalue of the internal pressure changes depending on the configuration ofthe generator, so that the internal pressure is not limited to thisvalue. An appropriate value of the internal pressure should be set tosuit each generator. These depressurizing and pressurizing keep thepressure inside the reformer in a proper state.

While the combustion is stopped, the evaporator 2 is heated by the airsupplied from the air supplying unit 11 to the combustor 4. However, theamount of heat supplied to the evaporator 2 differs between while thecombustion is stopped after the first combustion operation and while thecombustion is stopped after the second and following combustionoperations. When the combustion is stopped after the first combustion,the temperature of the entire reformer is not adequately increased, andthe reforming catalyst layer 3 tends to be heated locally. Therefore,when the air is supplied to the combustor 4 while the combustion isstopped, the amount of heat taken out from the reforming catalyst layer3 by the air flowing through the combustion gas passage is not so large,so that an effect of heating portions including the evaporator 2 otherthan the reformer cannot be expected so much. Therefore, the temperaturedetected by the reforming temperature detector 6, which is used as adetermination condition for proceeding from the stop state of the firstcombustion operation to the second combustion operation is set to behigher than the temperature detected by the reforming temperaturedetector 6, which is used as a determination condition for proceedingfrom the stop state of the second or following combustion operation tothe next (third or following) combustion operation. With this, theprocess can quickly proceed to the second or following combustionoperation to quickly heat the entire reformer. In the presentembodiment, as shown in FIG. 2, a second predetermined temperature(ignition temperature of the combustor 4) of the temperature detected bythe reforming temperature detector 6 is set to 300° C. as thedetermination condition used to proceed to the second combustionoperation, and the second predetermined temperature (ignitiontemperature of the combustor 4) of the temperature detected by thereforming temperature detector 6 is set to 250° C. as the determinationcondition used to proceed to the third and following combustionoperations. The determination condition (second predeterminedtemperature) for proceeding to the combustion operation is not limitedto these values, and changes depending on the configuration of thehydrogen generator 1, the type of the catalyst, the detecting method ofthe temperature detector, and the like. Note that the secondpredetermined temperature is set to be at least higher than such atemperature that the evaporator 2 cannot be increased in temperature bythe air which is supplied to the combustor 4 at the time of stopping ofthe combustion and is heated by the reforming catalyst layer 3.

When the temperature of the reformer becomes a predetermined temperatureor lower (150° C. or lower for example), the hydrogen generator 1 of thepresent embodiment carries out the start-up operation, i.e., the firstcombustion operation of the combustor 4 is started, and above-describedON and OFF of the combustion operation of the combustor 4 are carriedout. This predetermined temperature changes depending on theconfiguration of the hydrogen generator 1, the type of the catalyst, thedetecting method of the temperature detector, and the like.

When the temperature detected by the reforming temperature detector 6becomes the second predetermined temperature or lower, the control unit20 causes the air supplying unit 11 to change the amount of air suppliedfrom the air supplying unit 11 to the combustor 4 to the flow ratesuitable for the combustion, and causes the raw material supplying unit8 to start supplying the raw material to the reformer to supply thecombustion fuel to the combustor 4 again. With this, ignition is carriedout again by an ignition device (not shown) in the combustor 4, and theprocess can proceed to the combustion operation in the combustor 4.

When the temperature detected by the reforming temperature detector 6becomes the first predetermined temperature in an n-th combustionoperation, the control unit 20 determines whether or not the temperatureof the evaporator 2 is the water-evaporable temperature using theevaporator temperature detector 7. Hereinafter, the same operation asabove is repeatedly carried out until the temperature of the evaporator2 becomes the predetermined threshold or higher, i.e., thewater-evaporable temperature or higher.

In a case where the temperature of the evaporator 2 is increased to thepredetermined threshold or higher while the combustion operation of thecombustor 4 is stopped, and the reforming catalyst layer 3 is cooleddown by the air, the process may proceed to the combustion operation ofthe combustor 4 without decreasing the temperature of the reformer(reforming catalyst layer 3) to the determination condition forproceeding to the combustion operation.

FIG. 3 shows results obtained by compiling the operating conditions inthe first temperature increasing step of the hydrogen generator 1 in thepresent embodiment described above. As shown in FIG. 3, the raw materialflow rate, a fire extinguishing temperature (first predeterminedtemperature), the ignition temperature (second predeterminedtemperature), the air ratio, and the water-evaporable temperature arechanged among the first combustion operation, the second combustionoperation, and the third and following combustion operations. By theseoperations, the time taken to carry out the first temperature increasingstep (to be specific, the time taken to carry out the start-upoperation) is expected to be shortened. To be specific, in the presentembodiment, as show in FIG. 2, the time taken to carry out the firsttemperature increasing step is about 28 minutes, which is shorter thanthat in Comparative Example below.

Moreover, since the temperature of the evaporator 2 increases quickly,the number of times of the stop (OFF) of the combustion operation of thecombustor 4 is expected to be reduced, and the heat load repeatedlyapplied to the reformer is expected to be reduced. To be specific, inthe present embodiment, the number of times of OFF of the combustionoperation is twice, which is smaller than that in Comparative Examplebelow.

As Comparative Example with respect to the start-up operation of thehydrogen generator 1 of the present embodiment, the start-up operation(the first temperature increasing step and the second temperatureincreasing step) of the hydrogen generator is carried out using twooperating conditions different from those of the present embodiment.

FIG. 4 is a diagram schematically showing time-lapse changes of variousoperating conditions in the first temperature increasing step and (in upto an intermediate point of) the second temperature increasing step inanother start-up operation using the hydrogen generator.

As the operating conditions of the hydrogen generator shown in FIG. 4,the first predetermined temperature that is the reference temperaturefor determining whether or not the evaporator 2 can evaporate the wateris set to 370° C., and the temperature (second predeterminedtemperature) at which the combustion operation is restarted is set to300° C. In addition, the raw material flow rate is fixed to 1.5 NLM, theair ratio is fixed to a standard, and the water-evaporable temperatureis fixed to 85° C.

It can be seen in FIG. 4 that the time taken to carry out the firsttemperature increasing step is about 33 minutes, and the number of timesof OFF of the combustion operation is three times. Since the time takento carry out the first temperature increasing step in the presentembodiment is about 28 minutes, it is estimated that the time taken tostart up the hydrogen generator can be shortened about 5 minutes (about15%). Moreover, since the number of times of OFF of the combustionoperation in the present embodiment is twice, it is estimated that thenumber of times of OFF of the combustion operation can be reduced once.

FIG. 5 is a diagram schematically showing time-lapse changes of variousoperating conditions in the first temperature increasing step and (in upto an intermediate point of) the second temperature increasing step instill another start-up operation using the hydrogen generator.

As the operating conditions of the hydrogen generator shown in FIG. 5,the first predetermined temperature that is the reference temperaturefor determining whether or not the evaporator 2 can evaporate the wateris set to 320° C., and the temperature (second predeterminedtemperature) at which the combustion operation is restarted is set to300° C. In addition, the raw material flow rate is fixed to 1.5 NLM, theair ratio is fixed to the standard, and the water-evaporable temperatureis fixed to 85° C. That is, in accordance with the operating conditions,the temperature difference between the first predetermined temperatureand the second predetermined temperature is small, i.e., 20° C.

It can be seen in FIG. 5 that the time taken to carry out the firsttemperature increasing step is about 36 minutes, and the number of timesof OFF of the combustion operation is six times. Since the time taken tocarry out the first temperature increasing step in the presentembodiment is about 28 minutes, it is estimated that the time taken tostart up the hydrogen generator can be shortened about 8 minutes (about22%). Moreover, since the number of times of OFF of the combustionoperation in the present embodiment is twice, it is estimated that thenumber of times of OFF of the combustion operation can be reduced fourtimes.

The present embodiment explains the first temperature increasing step ofthe hydrogen generator 1 by dividing the combustion operation of thecombustor 4 into the first combustion operation, the second combustionoperation, and the third and following combustion operations. However,the above number of times of the combustion operation is just oneexample.

For example, the control unit 20 may control the combustion operation ofthe combustor 4 such that the heat amount per unit time by the combustor4 in the first combustion operation is larger than the heat amount perunit time in k-th (k>1) and following combustion operations. Similarly,the control unit 20 may control the combustion operation (fireextinguishing temperature) of the combustor 4 such that the temperatureof the reformer (reforming catalyst layer 3) when carrying out OFF ofthe first combustion operation of the combustor 4 is lower than thetemperature of the reformer (reforming catalyst layer 3) when carryingout OFF of the k-th (k>1) and following combustion operations. Theabove-described “k-th” is not limited to “second” exemplified in thepresent embodiment, but may be any number as long as it is the second ormore.

Moreover, the control unit 20 may control the combustion operation(ignition temperature) of the combustor 4 such that the temperature ofthe reformer (reforming catalyst layer 3) when carrying out ON of then-th and following combustion operations of the combustor 4 is lowerthan the temperature of the reformer (reforming catalyst layer 3) whencarrying out ON of an m-th (n>m>1) combustion operation of the combustor4. The above-described “m-th” is not limited to “second” in the presentembodiment, but may be any number as long as it is the second or more.Moreover, the above described “n-th and following” is not limited to“third” exemplified in the present embodiment, and may be any number aslong as it is more than the “m-th”.

Embodiment 2

Hereinafter, Embodiment 2 will be explained in reference to thedrawings.

FIG. 6 is a schematic block diagram showing the configuration of thefuel cell system according to Embodiment 2 of the present invention. Afuel cell system 200 includes the hydrogen generator 1 and a fuel cell101 as main components. The fuel cell 101 is, for example, a polymerelectrolyte fuel cell.

The hydrogen generator 1 is the hydrogen generator 1 of Embodiment 1,but includes a shift converter 30 and a CO remover 31 in addition to theabove-described reformer (shown as “reformer 1A” in FIG. 6) and thecombustor 4.

Specifically, the hydrogen-containing gas passage c of FIG. 1 isconnected to the shift converter 30, and the shift converter 30 and theCO remover 31 are connected to each other by a hydrogen-containing gaspassage d. In the hydrogen generator 1 configured as above, thehydrogen-containing gas generated by the reforming catalyst layer 3 issupplied to the shift converter 30 via the hydrogen-containing gaspassage c, and herein, a CO concentration of the hydrogen-containing gasis reduced by a shift reaction of carbon monoxide in thehydrogen-containing gas. The hydrogen-containing gas delivered from theshift converter 30 is supplied to the CO remover 31, and herein, the COconcentration of the hydrogen-containing gas is further reduced by anoxidation reaction of carbon monoxide in the hydrogen-containing gas.Since the shift converter 30 and the CO remover 31 carry out the aboveCO reducing process, the hydrogen-containing gas whose CO concentrationis low can be obtained in the hydrogen generator 1.

Note that the raw material supplying unit 8 of FIG. 1 is disposed on apassage through which the raw material is supplied from a raw materialsupply source to the reformer 1A, and the fuel supplying unit 10 of FIG.1 is disposed on a passage which branches off from the above passage andextends to the combustor 4.

In the fuel cell system 200, the hydrogen generator 1 is connected tothe fuel cell 101 to supply the hydrogen-containing gas to the fuel cell101. In addition, an oxidizing gas is supplied to the fuel cell 101.Hydrogen in the hydrogen-containing gas and oxygen in the oxidizing gasreact with each other in the fuel cell 101 to generate electric power.

In the operation of the fuel cell system 200, first, the hydrogengenerator 1 carries out the first temperature increasing step, thesecond temperature increasing step, and the hydrogen generating step asdescribed above. These steps have already been described in Embodiment1, so that explanations thereof are omitted here. As described inEmbodiment 1, the hydrogen generator 1 can shorten the time taken tocarry out the start-up operation, and can realize the operation which ishigh in durability performance. The start-up operation of the hydrogengenerator 1 in the present embodiment is such an operation that: thecontrol unit 20 (see FIG. 1) outputs the start-up command; the firsttemperature increasing step and the second temperature increasing stepare carried out; the reformer 1A starts the hydrogen generating step;the shift converter 30 and the CO remover 31 reduces carbon monoxide inthe hydrogen-containing gas to a level that the hydrogen-containing gascan be supplied to the fuel cell 101; and the supply of thehydrogen-containing gas, which is generated by the hydrogen generator 1,to the fuel cell starts.

When the carbon monoxide in the hydrogen-containing gas is adequatelyreduced as above, the hydrogen-containing gas generated by the hydrogengenerator 1 is supplied as the electric power generating fuel to a fuelelectrode of the fuel cell 101. Meanwhile, the air is supplied as theoxidizing gas to an air electrode of the fuel cell 101. In the fuel cell101, the supplied hydrogen gas and air react with each other(hereinafter referred to as an electric power generating reaction) togenerate electric power, and this electric power generating reactiongenerates heat. The electric power obtained by the electric powergenerating reaction is supplied to and used by an electric power loadterminal (not shown). Moreover, the heat generated by the electric powergenerating reaction is collected by heat collecting means (not shown),and utilized in various applications. For example, the heat can beutilized for hot water supply. Moreover, an unused hydrogen gas (socalled a fuel off gas), which is not utilized in the electric powergenerating reaction, is discharged from the fuel electrode of the fuelcell 101 to be supplied as the combustion fuel to the combustor 4 of thehydrogen generator 1.

Since the time taken to start up the hydrogen generator 1 can beshortened in the fuel cell system 200 of the present embodiment asdescribed above, the hydrogen gas can be supplied to the fuel cell 101in a short period of time. Therefore, the electric power energy and theheat energy can be supplied from the fuel cell system 200 in a shortperiod of time. On this account, it is possible to realize the fuel cellsystem 200 which excels in economical efficiency.

Embodiment 2 has explained an example in which the hydrogen generator 1described in Embodiment 1 is utilized as a hydrogen gas supplying deviceof the fuel cell system 200. However, the hydrogen generator 1 describedin Embodiment 1 is applicable to applications other than the hydrogengas supplying device of the fuel cell system.

From the foregoing explanation, many modifications and other embodimentsof the present invention are obvious to one skilled in the art.Therefore, the foregoing explanation should be interpreted only as anexample, and is provided for the purpose of teaching the best mode forcarrying out the present invention to one skilled in the art. Thestructures and/or functional details may be substantially modifiedwithin the spirit of the present invention.

INDUSTRIAL APPLICABILITY

The hydrogen generator according to the present invention is utilizableto generate hydrogen used in various applications, and for example, isuseful to generate a hydrogen gas used as a fuel gas of a fuel cell.Moreover, a fuel cell power generating system including the hydrogengenerator is utilizable as an electric power generator in variousapplications, and for example, is useful as a domestic fuel cellcogeneration system.

1. A hydrogen generator comprising: a reformer which generates ahydrogen-containing gas from a raw material and steam; a combustor whichheats the reformer; an evaporator which generates the steam by utilizingheat of a combustion gas after the reformer is heated by the combustiongas; and a control unit, the hydrogen generator being controlled suchthat ON and OFF of a combustion operation of the combustor are repeatedin a start-up operation of the hydrogen generator, and a temperature ofthe reformer is kept to a predetermined temperature or lower, whereinthe control unit controls the combustion operation such that a heatamount per unit time by the combustor in a first combustion operation islarger than a heat amount per unit time by the combustor in k-th (k>1)and following combustion operations.
 2. The hydrogen generator accordingto claim 1, wherein the control unit controls the combustion operationsuch that the temperature of the reformer when carrying out OFF of thefirst combustion operation of the combustor is lower than thetemperature of the reformer when carrying out OFF of the k-th (k>1) andfollowing combustion operations.
 3. The hydrogen generator according toclaim 1, wherein the control unit controls the combustion operation suchthat the temperature of the reformer when carrying out ON of n-th andfollowing combustion operations of the combustor is lower than thetemperature of the reformer when carrying out ON of an m-th (n>m>1)combustion operation of the combustor.
 4. The hydrogen generatoraccording to claim 1, further comprising a water supplying unit whichsupplies water to the evaporator, wherein when a temperature of theevaporator becomes a predetermined threshold or higher, the control unitdoes not carry out OFF of the combustion operation of the combustor butcontinues the combustion operation of the combustor, and causes thewater supplying unit to start supplying the water to the evaporator. 5.The hydrogen generator according to claim 4, wherein the predeterminedthreshold in the first combustion operation of the combustor is higherthan the predetermined threshold in m-th (m>1) and following combustionoperations.
 6. The hydrogen generator according to claim 1, wherein: thecombustor includes a burner which burns a combustion fuel and air, afuel supplying unit which supplies the combustion fuel to the burner,and an air supplying unit which supplies the air to the burner; and thecontrol unit controls the combustion operation such that an air ratio ofthe burner in m-th (m>1) and following combustion operations is higherthan an air ratio of the burner in the first combustion operation. 7.The hydrogen generator according to claim 6, wherein an amount of theair supplied to the burner while the combustion operation is stopped islarger than an amount of the air supplied to the burner during thecombustion operation.
 8. The hydrogen generator according to claim 6,wherein the air ratio at a time of ignition of the burner is lower thanthe air ratio in the combustion operation after the ignition of theburner.
 9. The hydrogen generator according to claim 7, wherein the airratio at a time of ignition of the burner is lower than the air ratio inthe combustion operation after the ignition of the burner.
 10. Thehydrogen generator according to claim 7, further comprising: a fuel gaspassage through which a gas delivered from the reformer is supplied tothe combustor; and a valve which is disposed on the fuel gas passage asthe fuel supplying unit, wherein the control unit opens the valve whenan internal pressure of the reformer reaches a predetermined thresholdor higher while the combustion operation of the combustor is stopped.11. The hydrogen generator according to claim 7, further comprising araw material supplying unit which supplies the raw material to thereformer, wherein the control unit causes the raw material supplyingunit to supply the raw material into the reformer when an internalpressure of the reformer becomes a predetermined threshold or lowerwhile the combustion operation of the combustor is stopped.
 12. A fuelcell system comprising: the hydrogen generator according to claim 1; anda fuel cell which generates electric power by using thehydrogen-containing gas supplied from the hydrogen generator and anoxidizing gas.